DIVERTING CARPET WASTE FROM LANDFILL. Simon Macaulay Anglo Recycling Technology Ltd

Transcription

1 DIVERTING CARPET WASTE FROM LANDFILL Simon Macaulay Anglo Recycling Technology Ltd

2 Anglo Recycling Technology Ltd 1. Introduction to Anglo 1. Case Studies - Recycling Car Tyres - Recycling Bulk IBC Bags - Recycling Carpet 1. Conclusion

3 Anglo Recycling Technology Ltd The Company Employees 35 Turnover (2010) approx 2.3m Material usage 1200 tonnes (90%+ recycled) Markets: Underlay, Horticulture, Automotive, Acoustic One Technical Business Development Manager Limited resources for product development Good reputation for innovation and customer service Often need partnerships and co-operation for: Ideas, Information, Resources, Cost Exploitation Good contacts and co-operation with Universities Want to be in control of new product developments Spend 3.5% of sales value on development Not afraid to co-operate and share info/resources

4 Reco Carpets Social enterprise alongside commercial company. Help for autistic adults 80% unemployed.

5 Working with Envirolink Northwest Anglo Recycling Technology Ltd Grand project support for car tyre recycling to commercial product IMO approval procedure for natural fibre underlay Ecobuild - exhibition support Carpet Recycling UK

6 Driving Innovation Vibro-acoustic products [H0222C] Need Finely divided wastes from range of industrial processes incur fee for disposal Drive to use more sustainable construction materials Approach Screen a wide range of waste materials for optimal properties One and two component foaming systems investigated Control of density critical to achieve desired properties Case Study Recycling Car Tyres Benefits Comparable thermal and improved acoustic performance to existing products. Potential to develop useful products from a range of waste materials

7 Driving Innovation Recycling of Flexible Intermediate Bulk Containers into Self-reinforced Composites Case Study Recycling Bulk IBC Bags Need: These orientated fibrous materials offer excellent mechanical properties with superb recyclability Polypropylene woven bags are currently sent to landfill at end-oflife Approach: Develop an approach for cleaning and recycling used bags Develop a manufacturing approach to use the recycled material with other materials to create a new type of composite material & technical end-use products / applications Woven bag: FIBC Green Roof Benefits: Reduce the amount of material going to landfill by up to 10,000 tonnes pa Recycling materials with addedcommercial value for use in lightweight composites and technical products

8 Benefits of CRUK Effective group for lobbying WRAP/ Government Co-operation and co-ordination with manufacturers and recyclers Catalysts for Innovation Ensure all European manufacturers bear their share of the cost

9 UK Carpet Waste Facts 420,000 tonnes per year ~ 250,000t polypropylene carpet ~ 100,000t wool-rich carpet ~ 65,000t carpet tile (nylon & bitumen) 10% residual waste in civic amenity sites 4.2 tco 2 e saving for every tonne recycled Low recycling rate ~2%

10 Policy Drivers Transition to a low-carbon economy Landfill diversion targets for local authorities Halving Waste to Landfill by 2012 Construction Industry Commitment Product Level producer responsibility & retailer take-back DEFRA consultation on landfill ban for textiles March 2010 Flooring Resource Efficiency Plan WRAP/BRE funded - July 2010

11 Penthouse Carpets Anglo Recycling - Mayfield Underlay Case Study Raw material: Recycling Carpet tonnes of wool and hessian top cloth and carpet edge trims from manufacturing process Challenges: Result: - Produce material of high enough quality short fibre lengths, not too dusty - Deal with latex binder Mayfield underlay, recycled top cloth -sole fibre source 100% recycled underlay, fabricated entirely from Penthouse wool rich carpet waste, with rubber backing from recycled tyres

12 Vertical Integration Closed Loop Recycling Products successfully pulled and used in nonwoven production Penthouse 80% wool carpet edges Vorwerk nylon brick carpet tiles post consumer Woollen clothing coats, jumpers Product Innovations 100% post consumer bonded underlay Fibres coated with SBR latex binder Fibres pass through oven for microbiological cleansing

13 Vertical integration means we can move quickly and pull products that our lines can run well. Produces lots of dust. Process does work! What have we learnt about pulling carpet fibre? It's a great story meets with public mood. UK at the forefront exporting to Australia Lots of blockages in Public sector procurement Fire risk

14 Conclusion Landfill costs increasing Government will further restrict landfill Can be difficult technically/logistically Need to open up markets Need to be price competitive